Inverter insulator apparatus and method

ABSTRACT

Disclosed embodiments include alignment apparatuses for circuit boards, inverter assemblies, and methods for fabricating an assembly with a circuit board placed on an alignment apparatus. An illustrative apparatus includes an electrically insulative substrate having a first substantially planar surface and a second substantially planar surface forming an opposing side of the first substantially planar surface. The second substantially planar surface defines therein self-aligning features that are configured to align at least one power module pin with the electrically insulative substrate. The first substantially planar surface has at least one alignment feature configured to align a printed circuit board with the electrically insulative substrate. The apparatus also includes a routing feature coupled to the electrically insulative substrate. The routing feature is configured to route at least one low voltage conductor.

INTRODUCTION

The present disclosure relates to assembly of inverter parts forelectric vehicles. The statements in this section merely providebackground information related to the present disclosure and may notconstitute prior art.

An inverter is an integral part of most electric vehicles which arepowered by direct current (DC) power packs to drive alternating current(AC) motors. The inverter power switching module is the main componentof the inverter and contains one or more electrical circuit boards. Oneboard of the inverter may be a gate drive board. The gate drive boardmay have a number of plated thru holes through which a number of contactpins must be fed through during assembly. This requires very precisealignment to do so. Alignment issues during assembly may cause assemblyfailures or component damages. Some inverter boards also do not alwaysprovide substantial electrical isolation from other parts and in someinstances also may lead to failure.

SUMMARY

Disclosed embodiments include alignment apparatuses for circuit boards,inverter assemblies, and methods for fabricating an assembly with acircuit board placed on an alignment apparatus.

In an illustrative embodiment an apparatus includes an electricallyinsulative substrate having a first substantially planar surface and asecond substantially planar surface forming an opposing side of thefirst substantially planar surface. The second substantially planarsurface defines therein self-aligning features that are configured toalign at least one power module pin with the electrically insulativesubstrate. The first substantially planar surface has at least onealignment feature configured to align a printed circuit board with theelectrically insulative substrate. The apparatus also includes a routingfeature coupled to the electrically insulative substrate. The routingfeature is configured to route at least one low voltage conductor.

In another illustrative embodiment an inverter assembly includes aninverter power module having at least one electrical connector pin. Theinverter assembly also includes a printed circuit board. Further, theinverter assembly includes an electrically insulative substrate having afirst substantially planar surface and a second substantially planarsurface forming an opposing side of the first substantially planarsurface. The second substantially planar surface defines thereinself-aligning features that are configured to align the at least oneelectrical connector pin with the electrically insulative substrate. Thefirst substantially planar surface has at least one alignment featureconfigured to align the printed circuit board with the electricallyinsulative substrate. Further still, a routing feature is coupled to theelectrically insulative substrate configured to rout at least one lowvoltage conductor coupled to the printed circuit board.

In another illustrative embodiment a method includes providing anelectrically insulative substrate having a first substantially planarsurface and a second substantially planar surface forming an opposingside of the first substantially planar surface. The second substantiallyplanar surface defines self-aligning features therein includingapertures defined therein and the first substantially planar surface hasat least one printed circuit board alignment feature. The method furtherincludes placing the electrically insulative substrate adjacent thesecond substantially planar surface such that at least one electricalconnector pin of a power module is extendible through at least oneaperture in the self-aligning features. Further still, the methodincludes placing a printed circuit board over the first substantiallyplanar surface being aligned with the at least one printed circuit boardalignment feature.

The foregoing summary is illustrative only and is not intended to be inany way limiting. In addition to the illustrative aspects, embodiments,and features described above, further aspects, embodiments, and featureswill become apparent by reference to the drawings and the followingdetailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments are illustrated in referenced figures of thedrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1 is a perspective view of an illustrative circuit board assemblywith an illustrative mounting component for electric inverter circuitryhaving circuitry mounted thereon.

FIGS. 2 and 3 are perspective views of a reverse side of the mountingcomponent of FIG. 1 .

FIG. 4 is a perspective view of the mounting component of FIG. 1 .

FIG. 5 is a flow chart of an illustrative method for fabricating theassembly of FIG. 1 .

Like reference symbols in the various drawings generally indicate likeelements.

DETAILED DESCRIPTION

In the following detailed description, reference is made to theaccompanying drawings, which form a part hereof. In the drawings,similar symbols typically identify similar components, unless contextdictates otherwise. The illustrative embodiments described in thedetailed description, drawings, and claims are not meant to be limiting.Other embodiments may be utilized, and other changes may be made,without departing from the spirit or scope of the subject matterpresented here.

Given by way of non-limiting overview, disclosed embodiments includealignment apparatuses for circuit boards, inverter assemblies, andmethods for fabricating methods for fabricating an assembly with acircuit board placed on an alignment apparatus.

Referring to FIG. 1 , in various embodiments an illustrative invertergate drive board assembly 100 includes an inverter gate drive circuitboard 110 having deposited thereon electrical circuit elements 115. Thecircuit board 110 may be mounted to an electrically insulative substrate120 having a first substantially planar surface 125 (FIG. 4 ). Thecircuit board 110 is aligned with the substrate 120 by insertingalignment fasteners or pins 129 into apertures 119 in the circuit board110. The substrate 120 includes a second substantially planar surface127 forming an opposing side of the first substantially planar surface125 (FIGS. 2 and 3 ). The second substantially planar surface 125 hasdefined therein self-aligning features 130 that are configured to alignat least one power module pin 140 with the electrically insulativesubstrate 120 and subsequently with the circuit board 110. The firstsubstantially planar surface 125 may have at least one alignmentfeature, such as, but not limited to, self-aligning features 130 thatare configured to align the printed circuit board 110 with the powermodule pins 140 that extend from an inverter power module 170. Theprinted circuit board may include any of a variety of electrical circuitelements and chips as well as including wiring connector ports, such asport 150 for connecting the printed circuit board with other devices andcontrollers.

In various embodiments, a routing feature 160 may be coupled to theelectrically insulative substrate 120, and the routing feature 160 maybe configured to rout at least one low voltage conductor or low voltageconductor harness through it. As depicted, the routing feature 160includes a post with an aperture therethrough. However, the routingfeature 160 is not limited to the configuration disclosed but may be anystructure that helps to rout or hold the low voltage conductor or lowvoltage harness in place.

In various embodiments, the self-aligning features 130 include partiallyconical shaped depressions formed in the second substantially planarsurface 127. Each of the self-aligning features 130 may be partiallyconical shaped depressions and may include an aperture which isconfigured to accommodate one or more power module pins 140 extendingtherethrough. These pins 140 are, when assembled, electrically coupledto circuit board 110. The number of pins 140 and self-aligning features130 should not be seen as limiting as any number of pins may be useddependent on the power module and inverter circuit design.

In various embodiments, an illustrative method of assembly 500 starts atblock 505. An electrically insulative substrate is provided at a block510. The insulative substrate has a first substantially planar surfaceand a second substantially planar surface forming an opposing side ofthe first substantially planar surface. The second substantially planarsurface defines self-aligning features therein including aperturesdefined therein and the first substantially planar surface has at leastone printed circuit board alignment feature. At a block 520, theelectrically insulative substrate is placed adjacent the secondsubstantially planar surface such that at least one electrical connectorpin of a power module is extendible through at least one aperture in theself-aligning features. At a block 530, a printed circuit board isplaced over the first substantially planar surface that is aligned withthe at least one printed circuit board alignment feature. The method 500stops at a block 535.

Illustrative embodiments may be used in constructing components ofelectric vehicles but are not limited thereto. The insulative substrate120, as generally configured, may help to resolve issues with aligninginverter power switching module pins with inverter gate drive printedcircuit boards during assembly. In various embodiments, twenty-one pinsare to be aligned. These twenty-one pins are to be fed through thruholes of a circuit board and be soldered. However, it will beappreciated that any number of pins may be used as desired for aparticular application and no limitation to any number of pinswhatsoever is intended to be implied and is not to be inferred.Misalignment of these pins to holes may contribute to causing damage toparts and may contribute to causing assembly failures. Adding theinsulative substrate 120 to hold down the circuit board and addingself-aligning features can help contribute to enabling simplifiedalignment. The self-aligning features, being partially conically shaped,can help contribute to enabling guiding alignment of the inverter modulepins through the circuit board thru holes.

In addition to helping address possible issues with module/pinalignment, the insulative substrate 120 may also provide electricalisolation between electrical connections and metal parts of the chassis.It will also be appreciated that the insulative substrate 120 may helpcontribute to providing harness routing features through which wiringharnesses can be threaded or supported.

In some instances, one or more components may be referred to herein as“configured to,” “configured by,” “configurable to,” “operable/operativeto,” “adapted/adaptable,” “able to,” “conformable/conformed to,” etc.Those skilled in the art will recognize that such terms (e.g.“configured to”) generally encompass active-state components and/orinactive-state components and/or standby-state components, unlesscontext requires otherwise.

While particular aspects of the present subject matter described hereinhave been shown and described, it will be apparent to those skilled inthe art that, based upon the teachings herein, changes and modificationsmay be made without departing from the subject matter described hereinand its broader aspects and, therefore, the appended claims are toencompass within their scope all such changes and modifications as arewithin the true spirit and scope of the subject matter described herein.It will be understood by those within the art that, in general, termsused herein, and especially in the appended claims (e.g., bodies of theappended claims) are generally intended as “open” terms (e.g., the term“including” should be interpreted as “including but not limited to,” theterm “having” should be interpreted as “having at least,” the term“includes” should be interpreted as “includes but is not limited to,”etc.). It will be further understood by those within the art that if aspecific number of an introduced claim recitation is intended, such anintent will be explicitly recited in the claim, and in the absence ofsuch recitation no such intent is present. For example, as an aid tounderstanding, the following appended claims may contain usage of theintroductory phrases “at least one” and “one or more” to introduce claimrecitations. However, the use of such phrases should not be construed toimply that the introduction of a claim recitation by the indefinitearticles “a” or “an” limits any particular claim containing suchintroduced claim recitation to claims containing only one suchrecitation, even when the same claim includes the introductory phrases“one or more” or “at least one” and indefinite articles such as “a” or“an” (e.g., “a” and/or “an” should typically be interpreted to mean “atleast one” or “one or more”); the same holds true for the use ofdefinite articles used to introduce claim recitations. In addition, evenif a specific number of an introduced claim recitation is explicitlyrecited, those skilled in the art will recognize that such recitationshould typically be interpreted to mean at least the recited number(e.g., the bare recitation of “two recitations,” without othermodifiers, typically means at least two recitations, or two or morerecitations). Furthermore, in those instances where a conventionanalogous to “at least one of A, B, and C, etc.” is used, in generalsuch a construction is intended in the sense one having skill in the artwould understand the convention (e.g., “a system having at least one ofA, B, and C” would include but not be limited to systems that have Aalone, B alone, C alone, A and B together, A and C together, B and Ctogether, and/or A, B, and C together, etc.). It will be furtherunderstood by those within the art that typically a disjunctive wordand/or phrase presenting two or more alternative terms, whether in thedescription, claims, or drawings, should be understood to contemplatethe possibilities of including one of the terms, either of the terms, orboth terms unless context dictates otherwise. For example, the phrase “Aor B” will be typically understood to include the possibilities of “A”or “B” or “A and B.”

With respect to the appended claims, those skilled in the art willappreciate that recited operations therein may generally be performed inany order. Also, although various operational flows are presented in asequence(s), it should be understood that the various operations may beperformed in other orders than those which are illustrated or may beperformed concurrently. Examples of such alternate orderings may includeoverlapping, interleaved, interrupted, reordered, incremental,preparatory, supplemental, simultaneous, reverse, or other variantorderings, unless context dictates otherwise. Furthermore, terms like“responsive to,” “related to,” or other past-tense adjectives aregenerally not intended to exclude such variants, unless context dictatesotherwise.

While the disclosed subject matter has been described in terms ofillustrative embodiments, it will be understood by those skilled in theart that various modifications can be made thereto without departingfrom the scope of the claimed subject matter as set forth in the claims.

What is claimed is:
 1. An apparatus comprising: an electricallyinsulative substrate having a first substantially planar surface and asecond substantially planar surface forming an opposing side of thefirst substantially planar surface, the second substantially planarsurface defining therein self-aligning features that are configured toalign at least one power module pin with the electrically insulativesubstrate, the self-aligning features including partially conical shapeddepressions formed in the second substantially planar surface, the firstsubstantially planar surface having at least one alignment featureconfigured to align a printed circuit board with the electricallyinsulative substrate; and a routing feature coupled to the electricallyinsulative substrate, the routing feature being configured to route atleast one low voltage conductor.
 2. The apparatus of claim 1, whereinthe self-aligning features include at least five partially conicalshaped depressions formed in the second substantially planar surface. 3.The apparatus of claim 2, wherein the self-aligning features include atleast ten partially conical shaped depressions formed in the secondsubstantially planar surface.
 4. The apparatus of claim 3, wherein theself-aligning features include at least twenty partially conical shapeddepressions formed in the second substantially planar surface.
 5. Theapparatus of claim 1, wherein the routing feature is configured toaccommodate a low voltage conductor harness.
 6. The apparatus of claim1, wherein the routing feature includes a post.
 7. The apparatus ofclaim 1, wherein the routing feature includes an aperture.
 8. Theapparatus of claim 1, wherein each of the partially conical shapeddepressions includes an aperture.
 9. An inverter assembly comprising: aninverter power module having at least one electrical connector pin; aprinted circuit board; an electrically insulative substrate having afirst substantially planar surface and a second substantially planarsurface forming an opposing side of the first substantially planarsurface, the second substantially planar surface defining thereinself-aligning features that are configured to align the at least oneelectrical connector pin with the electrically insulative substrate, theself-aligning features including partially conical shaped depressionsformed in the second substantially planar surface, the firstsubstantially planar surface having at least one alignment featureconfigured to align the printed circuit board with the electricallyinsulative substrate; and a routing feature coupled to the electricallyinsulative substrate configured to rout at least one low voltageconductor coupled to the printed circuit board.
 10. The inverterassembly of claim 9, wherein self-aligning features formed in the secondsubstantially planar surface include at least five partially conicalshaped depressions formed in the second substantially planar surface.11. The inverter assembly of claim 10, wherein self-aligning featuresformed in the second substantially planar surface include at least tenpartially conical shaped depressions formed in the second substantiallyplanar surface.
 12. The inverter assembly of claim 11, whereinself-aligning features formed in the second substantially planar surfaceinclude at least twenty partially conical shaped depressions formed inthe second substantially planar surface.
 13. The inverter assembly ofclaim 9, wherein the printed circuit board includes a gate drive board.14. The inverter assembly of claim 9, wherein the routing feature isconfigured to accommodate a low voltage conductor harness.
 15. Theinverter assembly of claim 9, wherein the routing feature includes apost.
 16. The inverter assembly of claim 9, wherein the routing featureincludes an aperture.
 17. The inverter assembly of claim 9, wherein eachof the partially conical shaped depressions includes an aperture.
 18. Amethod comprising: providing an electrically insulative substrate havinga first substantially planar surface and a second substantially planarsurface forming an opposing side of the first substantially planarsurface, the second substantially planar surface defining self-aligningfeatures therein including apertures defined therein, the self-aligningfeatures including partially conical shaped depressions formed in thesecond substantially planar surface, and the first substantially planarsurface having at least one printed circuit board alignment feature;placing the electrically insulative substrate adjacent the secondsubstantially planar surface such that at least one electrical connectorpin of a power module is extendible through at least one aperture in theself-aligning features; and placing a printed circuit board over thefirst substantially planar surface being aligned with the at least oneprinted circuit board alignment feature.